toller,

I have been watching this thread, but did not have time to write until
today. There seems to be a a multple of questions here and some
interesting thoughts among the responses.

First, If you glued the damaged board with epoxy and glassed also with
epoxy, there is no reason it will not last as long as the mohogan holds
out - that may be quite some time.

Mohogany is a relatively light wood, but not that light. You will pick
up probably 10-12 pounds. It was probably choosen for it's rot
resistance and the ease of working. It is a very dimensionally stable
wood which is why it is so valued by pattern makers.

By "cut the corners off" I am guessing that you mean the long edges. If
that is the case, we need to ask more questions here.
Are you going to make this cut the entire length of the blank?
If yes, just be sure you have pusher sticks handy and a friend to catch
the plank and trim as they come out of the saw. The second cut will be
much more exciting the than the first because of the small support area
left on the trailing edge.
If no, you still need the friend, but not the pusher sticks. Plus now
the operation has a new twist because sawblades only cant one way. In
one direction, you will have to start the cut as a pocket cut and saw
out of the blank, and the other you have to stop in the blank. There is
only one safe way to do this. Shut the saw down and then retract the
blade. You will have to finsh the cut by hand.

As to the actual section, yes, you can get there with the power plane
and belt sander (look up supergrit belts - effective prices). If the
boat is a class of any kind, the class site probably has the section
available. If not, you probably want a modified four digit. I own code
for this, but I do not know if it is available on the web - search.

Cutting guide reference slots is not a bad idea, you will have a lot of
wood to hack off before you get close to the sand-to-shape phase. You
might consider doing that before you even "cut the corners off" because
it will be easier to handle the blank then.

Thinking is the Cheap thing to do.

Matt Colie (I have been at this way too long)

Toller wrote:
My mahogany dagger board was damaged when I bought the boat used. I glued
it with epoxy and put some fiberglass around it and it has held up for a few
years, but I don't think it will last.

I bought some 8/4 white oak on ebay for almost nothing (100bf for $1.25),
and figured I will build a new daggerboard while I had something intact to
copy.

The blank is 44" long, 2" thick, and 15" wide. It weights 35 pounds.
I originally intended to cut the corners off on my table saw, but it is so
heavy that it doesn't seem particularly safe.
So, I have been going at it with my 3" belt sander and my 2" power planer.
Both would work, but they would take hours and hours of work.

Any suggestions for a good way to shape my blank into an airfoil shape?
I am thinking of buying a better planer, but hope someone here will be
resourceful.